Electrically powered motor vehicle

• US 4,216,839 A
• Filed: 07/20/1978
• Issued: 08/12/1980
• Est. Priority Date: 07/20/1978
• Status: Expired due to Term

• Current Assignee: Unique Mobility, Inc. (Danfoss A/S)
• Original Assignee: Unique Mobility, Inc. (Danfoss A/S)
• Inventors: Watson, Richard E., Eve, William R. IV, McCutchen, James V., Gould, John S., Pelcher, Anthony M., Winquist, Roger D.
• Primary Examiner(s): Love, John J.
• Assistant Examiner(s): Smith, Milton L.
• Application Number:
  US05/926,276
• Time in Patent Office: 754 Days
• Field of Search: 180/68.5, 180/65 R, 180/65 E, 180/60, 180/54 F, 180/55, 105/51, 105/50, 104/34, 429/100, 429/99, 429/96, 429/97, 429/98, 296/63, 296/64, 296/146, 297/DIG. 6, 267/20 R, 280/721, 280/722, 280/724, 280/725, 293/133, 293/121, 293/155, 293/119, 293/118, 293/116, 293/177, 49/41, 49/48
• US Class Current: 180/65.1
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/0427 Arrangement between the seats
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 3/0015 Prevention of collisions
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 53/80 Exchanging energy storage elements, e.g. removable batteries
• CPC Class Codes: B62D 29/046 Combined superstructure and frame, i.e. monocoque constructions
• CPC Class Codes: H01M 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors

Abstract

An electrically powered vehicle achieves maximum structural strength with minimum weight by utilizing a combined body and chassis formed entirely of plastic material, molded and bonded into an integral composite structure which includes a central, hollow longitudinal beam, top, bottom, and side panels of the vehicle body portion, and a power unit supporting chamber at the forward end closing the forward end of the beam and tying it to the side panels. The beam holds the batteries, and the chamber contains all of the components of the power unit including the controlling device. The structure is thus as rigid and light as possible, in addition to eliminating any possibility of any unwanted grounding or electrical paths. The only metal in the vehicle is that of the additional components such as road wheels, suspension members, steering, and power unit and the fasteners and brackets used to retain them in mounted position.

Claims

1. An electrically-powered motor vehicle comprising:

a combined body and chassis formed entirely of plastic material and molded and bonded into an integral composite structure;

the structure including a central longitudinal beam, top, bottom, and side panels of the vehicle body portion, and a power unit supporting chamber;

the beam being hollow and generally rectangular in section to serve as a compartment for the vehicle power cells and extending throughout a major portion of the length of the vehicle, and being closed at its forward end by the rear wall of the power unit supporting chamber, the aft end being openable for the insertion or removal of the power cells;

the bottom panel of the body portion being substantially at the same level as the bottom of the beam and providing a floor in the passenger compartment;

front and rear road wheels mounted by suspension means directly to the plastic structure;

said suspension means for the front wheels of the vehicle includes mounting means for front shock struts and front springs formed integrally with the upper rear portions of the side walls of the chamber; and

a horizontal reinforcing and stiffening brace is formed in the rear wall of said power unit supporting chamber and extends between the mounting means.

2. A vehicle as claimed in claim 1;

in which

the rear wall of the chamber extends across the vehicle and is united with the body portion side panels to tie them to the forward end of the beam and increase the torsional rigidity of the structure.

3. A vehicle as claimed in claim 1;

in which

the chamber contains at least an electric motor, a differential, and articulated drive shafts which extend laterally from the differential through apertures in the side walls of the chamber and which are connected at their outer ends to the front road wheels.

4. A vehicle as claimed in claim 3;

in which

a shiftable transmission is connected to the motor to be driven thereby, and is connected in driving relation to the differential.

5. A vehicle as claimed in claim 4;

in which

a removable rack is mounted in the chamber; and

the motor, transmission, and differential are supported from the rack and are removable as a unit therewith from the chamber.

6. A vehicle as claimed in claim 1;

in which

the chamber is closed at the bottom to prevent entry of dirt and water from the roadway to the power unit and to continue the streamlining of the bottom of the vehicle.

7. A vehicle as claimed in claim 1;

in which

rear seating is provided in the form of a primary shell extending from one side panel of the body portion to the other;

the shell having a bucket seat formation at each side and a central portion shaped to match the top and sides of the beam; and

the shell being bonded along its matching edges to the top and sides of the beam, the floor, and the side panels of the body portion to increase the torsional rigidity of the beam and the body portion.

8. A vehicle as claimed in claim 7;

in which

a passenger seat is mounted in each bucket seat formation;

each passenger seat has upholstery secured to the seat by hook and loop fastener means; and

each passenger seat is secured to its bucket seat formation by hook and loop fastener means.

9. A vehicle as claimed in claim 1;

in which

an opening is formed in each side panel of the body portion;

a door is hingedly mounted in each opening;

a window opening is formed in the upper portion of each door;

a first window pane is fixedly mounted in the aft portion of each window opening;

a second window pane is movably mounted in the forward portion of the window opening; and

the second pane is pivotally connected at its upper end to the window frame to swing rearward on occasion to a position laterally adjacent to the first pane to allow air passage through the door.

10. A vehicle as claimed in claim 9;

in which

the first pane is generally rectangular and its forward edge is substantially vertical;

the second pane is generally triangular, its aft edge is generally vertical in closed position adjacent to the forward edge of the first pane, and its forward edge is inclined downwardly and forwardly;

the pivotal mounting connection of the second pane to the window frame is at the upper apex of the triangle; and

the second pane is swingable rearward to a position in which its forward edge is substantially adjacent to the forward edge of the first pane.

11. A vehicle as claimed in claim 9;

in which

a securing means is provided to lock and hold the second pane in a desired position.

12. A vehicle as claimed in claim 11;

in which

said securing device is a threaded knob having a pane contacting bumper at one end and which is mounted in said door so that when the knob is turned, the bumper end can be moved into contact with the pane to hold it in position or moved away to allow the pane to swing to a different position.

13. A vehicle as claimed in claim 1;

in which

the aft end of the hollow beam is closed by a pivotally mounted door, said door having sealing means which seals the hollow compartment and securing means which holds the power cells in rigid position to prevent movement within the beam; and

vent means provided in said hollow beam whereby gasses within the beam are purged while the vehicle is in motion.

14. A vehicle as claimed in claim 1;

in which

a plurality of individual power cell trays is provided for insertion into the hollow beam;

each tray carries a plurality of power cells; and

the trays may be inserted end to end in the beam to provide enough power cells to supply the demand of the power unit.

15. A vehicle as claimed in claim 14;

in which

each tray is provided at each end with electrical contacts formed to mate with contacts on adjacent trays;

each contact is provided with an electrical terminal formed for connection to a conductor leading from an adjacent power cell; and

all of the contacts mate with their opposing contacts when the trays are inserted end to end in the beam to produce continuous circuitry from end to end of the column of trays.

16. A vehicle as claimed in claim 15;

in which

the rear wall of the chamber is provided, within the forward end of the beam, with electrical contacts located and formed to mate with the forward contacts of the foremost tray when the latter is in operating position; and

each contact on the chamber wall is provided with an electrical terminal within the chamber formed for connection to a conductor leading to the power unit within the chamber.

17. A vehicle as claimed in claim 14;

in which

each tray is made of plastic material and is provided on its bottom surface with slide strips of low friction plastic material.

18. A vehicle as claimed in claim 1;

in which

a bumper is provided extending across the width of the vehicle;

the bumper comprising an elongate base member connected to the vehicle by laterally spaced support members, and a thick, elongate contact member carried by the base member; and

the contact member being formed of a strong, resilient elastomeric material.

19. A vehicle as claimed in claim 18;

in which

the material of the contact member is a polyurethane compound.

20. A vehicle as claimed in claim 1;

in which

a bumper is provided extending across the width of the vehicle;

the bumper includes an elongate shock receiving member with a plurality of laterally spaced supports; and

the aft ends of the supports are attached to longitudinally yieldable shock absorber mountings.

21. A vehicle as claimed in claim 20;

in which each shock absorber mounting comprises a cylinder and a piston connected to the aft end of its respective support member and a body of extrudable material in the cylinder at the side of the piston opposite to the support member;

at least one extrusion port is provided in the cylinder wall in communication with the extrudable material; and

the material being sufficiently yieldable to be extruded through the port under the pressure of an abnormal force applied to the piston.

22. A vehicle as claimed in claim 1;

in which

a bumper is provided extending across the width of the vehicle;

the bumper includes an elongate shock receiving member with a plurality of elongate forwardly extending laterally spaced support members;

a socket for each support member is mounted on the aft end of the body portion;

each support member is formed to slide within its respective socket;

apertures are formed in each support member and socket and are arranged in registry with the bumper in operative position; and

lock pins are located in the respective registered apertures to prevent unintentional separation.

23. A vehicle as claimed in claim 1;

in which

a torsion beam extends laterally beneath the aft portion of the vehicle;

a pivotal mounting support is located at each side of the beam and is secured directly to the bottom panel of the body portion;

the ends of the beam are mounted in the pivotal supports;

a trailing arm is fixed to each end of the beam;

a rear road wheel is rotatably mounted on the free end of each trailing arm; and

a spring and shock strut are connected to each trailing arm adjacent to the respective wheels and to the bottom panel of the body portion.

24. A vehicle as claimed in claim 1;

in which

a gear shift lever means is provided in the driver'"'"'s compartment and connected to vehicle control equipment mounted in the chamber; and

the lever means is operable to move into at least forward and reverse positions to actuate the controlling equipment and to simulate driving operations of an internal combustion powered vehicle.

25. An electrically-powered motor vehicle comprising:

a combined body and chassis formed entirely of plastic material and molded and bonded into an integral composite structure;

the structure including a central longitudinal beam, top, bottom, and side panels of the vehicle body portion, and a power unit supporting chamber;

the beam being hollow and generally rectangular in section to serve as a compartment for the vehicle power cells and extending throughout a major portion of the length of the vehicle, and being closed at its forward end by the rear wall of the power unit supporting chamber, the aft end being openable for the insertion or removal of the power cell;

the bottom panel of the body portion being substantially at the same level as the bottom of the beam and providing a floor in the passenger compartment;

front and rear road wheels mounted by suspension means directly to the plastic structure;

a plurality of individual power cell trays is provided for insertion into the hollow beam;

each tray carries a plurality of power cells;

the trays being arranged to be inserted end to end in the beam to provide enough power to supply the demand of the power unit;

each tray is provided with a double-walled bottom providing a cavity within the bottom;

a plurality of apertures are formed in the lower wall to permit overflow of pressurized air from the cavity to the exterior below the bottom; and

an inlet port is provided in the tray communicating with the interior of the cavity to provide a flow path for pressurized air to enter the cavity from an external source.

26. An electrically-powered motor vehicle comprising:

a combined body and chassis formed entirely of plastic material and molded and bonded into an integral composite structure;

the structure including a central longitudinal beam, top, bottom, and side panels of the vehicle body portion, and a power unit supporting chamber;

the beam being hollow and generally rectangular in section to sever as a compartment for the vehicle power cells and extending throughout a major portion of the length of the vehicle, and being closed at its forward end by the rear wall of the power unit supporting chamber, the aft end being openable for the insertion or removal of the power cell;

the bottom panel of the body portion being substantially at the same level as the bottom of the beam and providing a floor in the passenger compartment;

front and rear road wheels mounted by suspension means directly to the plastic structure;

a bumper is provided extending across the width of the vehicle;

the bumper includes an elongate shock receiving member with a plurality of elongate, laterally spaced, support member;

a socket for each support member is mounted on the aft end of the body portion;

each support member is formed to slide within its respective socket;

apertures are formed in each support member and socket and are arranged in registry with the bumper in operative position;

lock pins are located in the respective registered apertures to prevent unintentional separation;

a second socket is mounted on the body portion forward of and in alignment with each first socket;

each support member is of sufficient length to enter into the second socket when the bumper is in operative position;

a stop is secured to each support member to limit the extent of its removal from its first socket;

each first socket is pivotally mounted for swinging in a vertical plane to allow the bumper to be lowered out of the path of the power cells when the stops engage the first socket; and

an abutment is provided on the body portion to engage the inner portion of each support member as it swings upward to limit the extent of lowering of the bumper.

27. An electrically-powered motor vehicle comprising:

a combined body and chassis formed entirely of plastic material and molded and bonded into an integral composite structure;

the structure including a central longitudinal beam, top, bottom, and side panels of the vehicle body portion, and a power unit supporting chamber;

the beam being hollow and generally rectangular in section to serve as a compartment for the vehicle power cells and extending throughout a major portion of the length of the vehicle, and being closed at its forward end by the rear wall of the power unit supporting chamber, the aft end being openable for the insertion or removal of the power cell;

the bottom panel of the body portion being substantially at the same level as the bottom of the beam and providing a floor in the passenger compartment;

front and rear road wheels mounted by suspension means directly to the plastic structure;

the power unit supporting chamber contains at least an electric motor, transmission, differential, and articulated drive shafts which extend laterally from the differential through apertures in the side walls of the chamber and which are connected at their outer ends to the front road wheels;

a means is provided for electrically controlling the operation of the electric motor; and

said controlling means is operatively connected to a variable position lever means controllable by an operator of said vehicle, said lever means being arranged whereby a first portion of travel of said lever means controls the speed of said motor while the remaining portion of travel controls the variable torque characteristics of the transmission while the motor is maintained at maximum speed.